LAB

MANUAL

DEPARTMENT OF AUTOMOBILE ENGINEERING

TWO & THREE WHEELER SERVICE

SUBJECT:
LAB
&MINI PROJECT

CODE: 4059

SEMESTE 4 TH
R:

REVISION: 2015
Department Vision

To provide highly competent, efficient manpower to meet the ever-changing needs of

the global automotive industry and the society.

Department Mission

 To impart quality education and training to the students.

 To prepare students for creative thinking and innovativeness.
 To fulfill Industrial requirements globally by Imparting Innovative Knowledge, Ethical
values and Collaborative works.

Program Educational Objectives (PEO’s)

PEO 1:-Students will apply knowledge of automotive engineering & practices to pursue
successful career in the field of automotive technology.

PEO 2:-Students will contribute to the academics and research for socio-technological
development.

PEO 3:-Students will demonstrate lifelong learning skills by engaging in professional

activities and up-gradation of knowledge quotient.

Program Specific Outcomes

PSO1:-Diagnose the automotive system failures and repair / replace the components
/ systems so as to bring the vehicle in original condition.

PSO2:-Perform the role of motor claim approver and loss assessor with confidence and
competence.

PSO3:-Use relevant machinery, materials, equipment and processes to

manufacture automobile components.
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STUDY NO:1
DATE:

STUDY OF THREE WHEELER CHASSIS FRAME AND

POWER TRANSMISSION SYSTEM.
AIM :

To study the various features and measure the various dimension of the chassis frame of
three wheeler and power transmission system.

TOOLS REQUIRED :

Measuring tape.

PROCEDURE :

Using the measuring tape, note that

Wheelbase: It is the distance between the centre points of front wheel to the centre point of rear
wheel.
Wheel track: It is the distance between the centre points of two rear wheels.
Over all length: It is the through out distance between front side to the vehicle.
Over all width: It is the distance taken from top portion of the vehicle to the ground level.
Ground clearance: It is the distance taken between nearest part or portion towards ground level.
(ex: differential)

POWER TRANSMISSION SYSTEM :

The system by which the power from engine is transmitted to the wheels is called
transmission system. Transmission system carries engine power to the rear wheel. Power at the rear
wheels move the vehicle forward overcoming external forces. Clutch is located between the engine
and gearbox. Clutch transmits engine power to the gearbox. In Three-wheeler, multiple clutches is
used. When the clutch is in the disengaged position, the power transfer is interrupted. Such power
interruption will enable shifting of gears smoothly with out damaging gear teeth. Gearbox provides
different torque at the rear wheel according to the requirements by engaging different gear
combination.

PROPELLER SHAFT DRIVE :

This system is mostly used in three-wheeler. Like four wheelers, the propeller shaft in this
system also consists of a sliding joint at one end and universal joints at both the ends.

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RESULT :

Thus the various features of the chassis are studied & its dimensions have been measured and
the power transmission system also studied.

THREE WHEELER CHASSIS FRAME

TRANSMISSION SYSTEM

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STUDY OF TWO WHEELER CHASSIS FRAMES

Aim
To study the various features and various types of two wheeler frames.

The cost of the mainframe of any motorcycle is highly dependent on the type of chassis in it and also on
the type of material which is used for production. Steel has been the traditional choice for chassis
material. It is cost-effective and provides reasonable strength and stability for low level and moderate
level performance but with the advancement, in material sciences, Aluminium and some alloys now make
up the chassis providing lightweight and the required amount of rigidity. More expensive materials have
been discovered for the best in class performance motorcycles which make use of Carbon fibre,
Magnesium and Titanium.

1. Backbone frame
This is the most basic constituent of the array. This is just a spine-like frame holding on to
different parts and not a full-fledged skeleton. The amount of material used is less and the
engine is bolted on the spine, so it is not a stressed member.

Advantages- It is cost-effective and finds its use in the entry-level products which have
low power needs.
Disadvantages- It lacks strength and torsional rigidity.

2. Single cradle frame

It is also called a single down tube frame and is a combination of steel tubes welded
together in a pattern which is analogous to that of a bicycle. Thus a motorcycle built on
this frame resembles a solidly built bicycle. This is another basic frame and finds
applications in products which are built by taking cost in mind. A frame is considered
cradled if the engine is a stressed member or in other words, if the engine is cradled in the
chassis.
Advantages- It is a cost-effective and good choice for low power vehicles.
Disadvantages- Cannot be used in performance-based products, for reasons similar to the
backbone frame.

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2. Double cradle frame

This is very similar to the single cradle frame and the only difference lies in the engine
support. In the single cradle frame, one steel tube goes underneath the engine and supports
it whereas in a double-cradle frame the engine is supported by two tubes, Thus providing
better strength and structural rigidity.

Advantages- This frame is better than the other basic frames and is the strikes the best
balance between quality and cost in a price-conscious market.
Disadvantages- The design is kind of old and outdated and cannot be relied on for a
performance-specific product and other higher-cost offerings.

3. Perimeter frame

The perimeter frame or the twin-spar frame is the popular choice when it comes to
performance-based motorcycles. Research, based on motorcycle racing found out that
there is a noticeable increase in rigidity when the steering hand is connected to swing arm
in the shortest possible distance. The rods connecting these should be adequately stiff and
results improve with a decrease in weight. Two beams (twin spars) reaching out to the
pivot arm surround the engine and that’s where the name twin-spar frame comes from.
Earlier these spars were made of steel but lightweight aluminium took its place in the
modern world.

Advantages- This is the most popular choice for performance-based motorcycles.

Disadvantages- There have been complaints of reduced power in some motorcycles using
the perimeter frame when compared to the trellis frame.

4. Trellis frame
The trellis frameworks on the same principle as the perimeter frame. The primary
objective is to connect the steering bar to the swingarm. The difference lies in the way the
connectors are constructed. In the trellis frame, steel or aluminium tubes are welded
together to form a trellis-like structure.
Advantages- The trellis frame is lighter and easier to construct and it aces the lightweight
construction.
Disadvantages- It is the best among a huge class of motorcycles, but for most extreme
cases, monocoque frame takes the lead.
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Single cradle frame Double cradle frame

Perimeter frame

Trellis frame

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STUDY OF TWO WHEELER TRANSMISSION SYSTEM

Analyzing a power flow diagram is a great way to understand how a motorcycle

transmission works. This power flow diagram shows what happens when a motorcycle is
in first gear:

1. Engine power enters the transmission main shaft via the clutch.
2. Gear M1 is a fixed gear (spins at same speed as the main shaft).
3. Gear C1 (freewheeling gear) is in constant mesh with M1.
4. C5 is a slider gear; when it engages C1, the countershaft spins.
5. Power exits the transmission via the sprocket to the drive chain.
This power flow diagram shows what happens to the transmission when the motorcycle is
in fourth gear:

1. Engine power enters the transmission main shaft via the clutch.
2. Gear M4 is a fixed gear (spins at the same speed as the main shaft).
3. Gear C4 (freewheeling gear) is in constant mesh with M4.
4. C2 is a slider gear; when it engages C4, the countershaft spins.
5. Power exits the transmission via the sprocket to the drive chain.

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And this power flow diagram shows what happens to the transmission when the motorcycle
is in neutral:

1. Power enters the transmission main shaft via the clutch.

2. All three fixed gears (M1, M4 and C3) mesh with freewheeling gears.

3. The countershaft does not spin.

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EXP NO:
DATE:

ADJUSTING OF BRAKE PEDAL FREE PLAY IN TWO WHEELER

AIM:To adjust the free play of brake pedal

OBJECTIVES:Checking and adjustment of brake

TOOLS AND MATERIAL REQUIRED:Double end spanner set,Cotton waste,Grease,Oil ….

PROCEDURE:
*Park the vehicle in centre stand
*Check the brake pedal play
*If it is exceed as per company recommended (25-30mm)
*Then tighten the adjusting nut present at the end of brake linkage
*Check the brake pedal play using steel rule
*Set it as per specified
*Lubricate the brake linkages with oil and grease
*Run the vehicle and check the performance

RESULT
Then checked and adjusted the brake pedal free play of two wheeler

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EXP NO:
DATE:

ADJUSTING OF CLUTCH PEDAL FREE PLAY IN TWO WHEELAR

AIM:To adjust the free play of clutch pedal

OBJECTIVES:Checking and adjustment ofclutch

TOOLS AND MATERIAL REQUIRED:Double end spanner set,Cotton waste,Grease,Oil ….

PROCEDURE:

 PARK THE VEHICLE IN CENTRE STAND

 CHECK THE CLUTCH LIVER FREE PLAY
 LOOSEN THE LOCK NUT IN CLUTCH LIVER END SIDE.
 TURN THE ADJUSTING NUT TO OBTAIN THE SPECIFIED FREE PLAY(10-20MM).
 TIGHTEN THE LOCK NUT AND CHECK THE ADJUSTMENT
 START THE ENGINE, PRESS THE CLUTCH LEVER AND SHIFT INTO GEAR.
 MAKE SURE THE ENGINE DOES NOT STALL AND THE MOTORCYCLE DOES NOT CREEP.
 GRADUALLY RELEASE THE CLUTCH LEVER AND OPEN THE THROTTLE.
 THE MOTORCYCLE SHOULD START SMOOTHLY AND ACCELERATE.

RESULT
Then checked and adjusted the clutch lever free play of two wheeler

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EXP NO:
DATE:

ADJUSTMENT or CENTERING OF TWO WHEELER STEERING

AIM:To adjust and center the two wheeler steering

TOOLS AND MATERIAL REQUIRED:Spanner set , grease, oil….

PROCEDURE:
 Check that the control cables do not interfere with the handlebar rotation.
 Check for smooth action & maneuverability.
 Park the motorcycle on its main stand and raise the front wheel off the ground.
 check that the handlebar rotates freely from side to side.
 If the handlebar moves unevenly, binds, or has play, inspect and adjust the steering head
bearings.
 Check for worn steering stem bearings by grabbing the front fork leg and attempting to
move the front for side to side.
 Adjust/replace the bearings if any play is observed.

RESULT
Studied and adjusted the steering of two wheeler.

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EXP NO:
DATE:
DISMANTLING AND ASSEMBLING OF CHAIN
AIM:
DISMANTLING AND ASSEMBLING OF CHAIN

TOOLS REQUIRED AND MATERIAL REQUIRED:

SPANNER SET, SCREW DRIVER , COMBINATION PLIER, COTTON WASTE, KEROSENE, ….

PROCEDURE:
1. PARK THE VEHICLE ON A LEVEL GROUND
2. KEEP THE VEHICLE ON CENTRE STAND
3. REMOVE THE SOCKET SIDE COVER AND CHAIN COVER
4. ROTATE THE TYRE WITH NEUTRAL POSITION AND FIND THE LOCK PIN AND
UNLOCK IT
5. REMOVE CHAIN AND CLEAN WITH KEROSENE
6. REFIT THE CHAIN FROM SOCKET SIDE AND LOCK THE LOCK PIN IN TYRE SIDE
7. ADJUST THE CHAIN TENSION WITH ADJUSTING NUT
8. START THE ENGINE AND RUN TO CHECK THE PERFORMANCE

RESULT
DISMANTLED AND ASSEMBLED THE CHAIN FROM GIVEN VEHICLE

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2.LOCK PIN

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